Grinding Process Solutions (GPS)

Grinding Process Solutions (GPS)

Introduction

I implemented a new business initiative, Grinding Process Solutions (GPS) in partnership with STIMS Institute, USA that enhances the basic MGT business of selling machine tools. The idea here is to develop Micromatic Grinding Tech. Ltd. (MGTL) into a full service company, providing complete grinding system solutions catering to a wide variety of requirements of its customers.

It has been conceived as a service solution offering for the manufacturing industry, much similar in nature to the IT services offered by companies such as Infosys, TCS and Wipro. Hence, GPS solutions are available for all grinding applications and are independent of the machine tool brand.

GPS aims to provide significant improvements in existing manufacturing processes by integrating manufacturing knowledge with a scientific basis (cause/effect based on the physics of the process) through a System Approach and through the use of MGT’s proprietary diagnostic tool Grind TrakTM developed with support of Dr. K. Subramanian of STIMS Ins. USA.

GPS-Methodology

GPS-Methodology

 

Organization

We work as a small expert team under Dr. K. (Subbu) Subramanian‘s guidance, to carry out the projects under GPS. The projects of GPS come under the purview of “value selling”  and therefore require the buy-in of the high-level management of the client.

After the initial interaction of the top-level management, the lead is handed over to the GPS team. The major activities are:

  1. Preparation of the proposal
    • Understanding the customer requirement
    • Preliminary documentation
    • Estimating the value of the project to the customer
    • Making the proposal
    • Internal Review
    • Submitting the proposal
    • Customer Approval – Deliverables, time-line and cost.
  2. Project Execution
    1. Diagnostics
      • Detailed system documentation
      • Grind Trak studies
      • Capturing other process and quality data
      • Analysis of the in-process signals
      • Recommendations for solution (incorporating customer constraints)
    2. Implementation
      • Implementation of the solutions
      • Documentation of the impact of the solution
  3. Project Report and Closure
    • Making the report
    • Agreement of scope completion
    • Project closure

I’m leading a team of 4 people within MGTL for the GPS related activities. My major contributions are in the areas of proposal preparation and identification and solution of the problem based on the analysis of data.

Accomplishments

The team has executed over 10 internal projects and 1 external project so far, which was a paid service.

Significant improvements in the line productivity can be achieved by identifying and eliminating the bottleneck operation. In many cases, this is possible by modifications to the process as is shown in the graph below. The initial cycle had a high cycle time with an extended finishing cycle to achieve the desired surface finish. By modifying the dressing and the grinding parameters together, the same can be achieved in a much lower cycle time. By strategically attacking the bottleneck operation, the line throughput was increased by more than 30% without any additional investment.

GPS_CaseStudy

Case Study – the cycle time reduction of almost 50% in the bottleneck operation resulted in over 30% increase in line throughput.